March 23, 2002  6.5 hours 

Installed the Duckworks landing light in the left leading edge.  This was sure simple to take as much time as it did.  Of course, I had the interruptions of NCAA basketball tournament to work around (-:.  Here's the contents of the kit.  Looks like maybe a couple hours to complete. Wrong! 

The first step is to mark where the cut out will be using the template provided.

  Double checking the measurements.  18.75 inches from leading edge top skin.  

  After marking, double checking the measurements, then triple checking the measurements and then quadruple checking the measurements, it's time to cut this perfectly good leading edge skin.  I used a dremel type tool with a small cutting disc to cut the straight edges. 

 Then used a carbide cutting bit to cut the curves. 

After cutting the hole, I used a Vizen file to straighten up the edges and a scotch brite wheel to finish up the cuts.  You then drill six holes that will hold the lens in place.  They provide a couple of doublers that are pre-drilled so I used those as the template.

 This is the assembled bracket with the light installed.  I did prime this and started to go get some appliance white paint .  I thought that this would give more reflection, but I didn't want to run to the store.  Maybe later.  You only use the bulb and the reflector from the light, discarding the light bracket.

  I used duct tape as handles to hold the lens in place and to add some back pressure while drilling the holes in the lens.  

The finished product.  Pretty simple product to install, just time consuming.  I would definitely install the landing lights before mounting the leading edge to the wing.  I turned the leading edge every direction while installing the light.  I think it would be much more difficult to install with the leading edge already mounted. 

The last thing I did today was to machine countersink and then prime the countersinks in the main wing spar where the leading edge is attached.  I just used a rattle can of NAPA 7220 to prime this small section.

March 24,2002  4 hours

I permanently installed the left leading edge today.  It took me a couple of hours to get everything in place and rivet the ribs to the spar and then about an hour to squeeze the skin to spar. 

I finished up by "roughing" up the ribs that go into the tank in preparation of prosealing them into the tank. I used a nylon brush on the die grinder instead of the stainless steel brush.   I also made a clip to hold the fitting that goes through the inboard rib and attaches to the flop tube.  The plans do not call for this but in playing with the flop tube, it seemed that the movement of the flop tube could easily cause the fitting to work loose.

April 4, 2002  1.5 hours

I spent time cleaning up the work area from the Proseal experience. I also added the most inboard rib between the main wing spar and the rear wing spar.  This rib was originally backordered when the kit arrived.  This worked extremely well without any planning on my part.  Not installing this rib allowed more room to get to the three nut plates used to hold the most inboard "Z" bracket for the fuel tank.  I'm waiting on some wire to come in to install on the sending unit of the fuel gauge before installing the tank and then the skins.  Actually, using this as an excuse to take a little break from building this week.

April 6, 2002  4 hours

Today was one of those days that you look back and wonder what it was that you did.  The wire for the fuel sender should be delivered Monday and then I can install the tank onto the spar and get started back in earnest. 

I did get the flap brackets drilled to the spar.  As with everything else, once I get one side in place, I try to prepare the other wing parts as well.  It'll save time in the long run.

These are the flap braces.  I countersunk these where they attach to the skin.  The hinge that attaches the flap lays on top of these seals.  I countersunk these instead of dimpling them so the hinge would lay flat instead or riding on the dimples. 

These are the aileron seals.  I dimpled these where they attach to the skins. They are not thick enough to countersink and nothing lays on top of these either.

I only had enough rattle can primer to prime the pieces for the left wing.  I didn't want to rig up for spraying with the spray gun.  I'll either get some more primer in a can or prime the rest when priming the ailerons and flaps.

I smeared fuel lube over the bearings to keep the primer out of the bearings. 

I attached nut plates to the skin for the access plates.  I also dimpled the access cover plates.  Again, no brainer type work, but somewhat time consuming.